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Material Science of 3D Printing Filaments

Material Science of 3D Printing Filaments. Milwaukee 3D Meet Up Coex3D 11-2-2013. Topics. Filament Manufacturing Upstream Extrusion Down Stream Polymer Science 101 Monomers Morphology Melt Behavior Filaments Discussion. Filament Manufacturing.

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Material Science of 3D Printing Filaments

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  1. Material Science of 3D Printing Filaments Milwaukee 3D Meet Up Coex3D 11-2-2013

  2. Topics • Filament Manufacturing • Upstream • Extrusion • Down Stream • Polymer Science 101 • Monomers • Morphology • Melt Behavior • Filaments • Discussion

  3. Filament Manufacturing

  4. Filament ManufacturingUp-Stream Processing Resin Drying • Critical steps in resin processing • Hydrophilic resins needs to be dried to make 3D filament • PLA, PET, PC, PA, PVOH are highly Hydrophilic • ABS slightly Hydrophilic

  5. Filament ManufacturingUp-Stream Processing Resin Drying

  6. Filament ManufacturingUp-Stream Processing • Color Feeders • Color concentrates • Additives • Throat Mixers • Magnet

  7. Filament ManufacturingReal Extruders Extruder Elements • Zone Heated Barrel • Screw • Screen Pack • Breaker Plate

  8. Filament ManufacturingReal Extruders • Process Conditions on Extruders • Melt Temperature • Melt Pressure • RPMs • Motor Load

  9. Filament ManufacturingReal Extruders Extruder Screws • Feeding • Melting • Compression • Mixing • Material Specific

  10. Filament ManufacturingWater Quench Water Bath • Filaments are often water quenched • Molten phase to solid phase • Methods are often trade secret • 10-30 feet water cooling

  11. Filament ManufacturingFilament Orientation

  12. Filament ManufacturingLaser Micrometer

  13. Filament ManufacturingSpooling

  14. Filament ManufacturingPackaging

  15. Polymer Science for 3D Printers

  16. Polymer Science 101 for 3D PrintersPlastic vs. Polymer Plastic • Plastics are polymers which, under appropriate conditions of temperature and pressure, can be molded or shaped. Polymer • A large molecule formed by the chemical union of five or more identical combining units called monomers

  17. Polymers Science 101Monomers • Number of monomers (Molecular Weight) influences viscosity and strength properties • (wax 30-350 RU, PP 7,000 – 24,000 RU) • Types and location of the monomer influence polymer chemical and mechanical properties

  18. Polymers Science 101Morphology

  19. Polymers Science 101Melt Behavior - Viscosity • Viscosity • Melt Index Test (MI or MFR) • Mass/Time @ Temp & Weight • 3D Printing Filaments are typically injection molding resin grades • 10+g/10 min @ 220°C 10kg • Lower MI or MFR would require more force on filament advance • Intrinsic viscosity (IV) is used to measure viscosity for polymers like PET

  20. Polymers Science 101Melt Behavior – Melting Temps • Thermal Transitions • Glass Transition – Amorphous materials flow, they do not melt • Melting Point – The temp at which a crystalline structure transitions to a liquid Amorphous structure

  21. 3D Printing Filaments

  22. Polymer Science 101Polylactide (PLA) - General Polylactide (PLA) • Biopolymer - derived from corn • Relatively clean resin • Condensation reaction • Translucent • Translucent Blue

  23. Polymer Science 101Polylactide Polylactide (PLA) • Morphology • Semi-crystalline polymers • Filament production method and colorants will change crystalinity levels • Resin has a Tg 55-60°C & Tm of 145-160°C • Different processing temps on printer (≈220°C) • Melt Behavior • MFR: 6 g/10 min (210°C & 2.16 Kg) • Monomer • Latic Acid • Density: 1.24 g/cc

  24. Polymer Science 101ABS Acrylonitrile Butadiene Styrene • Derived from 3 monomers • Monomers % - Properties • Not a clean resin to extrude • Opaque

  25. Polymer Science 101ABS Acrylonitrile Butadiene Styrene (ABS) • Morphology • Amorphous • Grade dependent Tg100°C - 130°C • Melt Behavior • MFR: 1.1 g/10 min (200° C & 5 Kg) • MFR: 13g/10 min (220° C & 10 Kg) • Monomer • Acrylonitrile, Styrene & Butadiene • Density: 1.03 g/cc

  26. Polymer Science 101PVOH PVOH • Water soluble polymer • Commonly used in 3D Printing for structural elements that are dissolved after print is complete • Narrow gap between PVOH melting temp and thermal degradation – run as cool as possible • Keep Dry when not in use

  27. Polymer Science 101CX-Glass & CoPET CoPET (Developmental) • Copolyester polymer • Clean polymer • Morphology • Amorphous • Melt Behavior • MFR: 10 g/10 min (220° C & 10 Kg) • Clear • CX-Glass(Developmental) • Glass like polymer • Extremely clean polymer • Morphology • Amorphous • Melt Behavior • MFR: 13g/10 min (220° C & 10 Kg) • Clear • Heated bed required

  28. Polymer Science 101CX-Glass & CoPET

  29. Thank YouIf you would like a copy of the presentation just drop me an email atSales@CoexLLC.comOr coex3d.com/contact

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